19FEBRUARY 2026Compressed air is becoming a strategic lever where intelligent systems deliver measurable energy savings while improving reliability and helping manufacturers meet rising uptime and sustainability expectationsManufacturers are increasingly using sensor-based compressed air monitoring to achieve this. Our latest compressors come pre-equipped with IoT connectivity, securely transmitting key parameters such as pressure, temperature, run hours, power consumption and alarms for continuous monitoring. This gives plant teams real-time visibility, data-driven insights and early warning of anomalies, empowering manufacturers to optimize operating costs and total cost of ownership.One such example is ELGi's Air Alert system, which takes this capability a step further. It provides 24/7 remote moni-toring, intelligent algorithms that predict commonly occurring failures, and proactive alerts for faults and upcoming service needs, delivered via easy-to-read dashboards and reports. Cus-tomers can schedule maintenance at convenient windows, en-sure resilient, disruption-free operations and improve energy efficiency by acting on utilisation trends and leak indicators. In high-throughput industries such as textiles, automotive and general engineering, this approach to compressed air sys-tems is already translating into higher uptime, lower mainte-nance costs and more stable, reliable operations. This is not just about cost optimization and sustainability gains, it's about shaping a future-ready, low-carbon manufacturing ecosystem. These digital capabilities position manufacturers at the fore-front of Industry 4.0, enabling predictive insights and agile de-cision-making.Given that many Indian plants still run on overdesigned or outdated compressor systems, what's driving the shift toward retrofitting with energy-optimized, smart air solutions?Across India, many plants still operate oversized or legacy fixed-speed compressors that cycle heavily between load and unload, wasting energy and creating unstable pressure. Rising electricity costs, tighter efficiency norms, and the need to improve reliability without replacing entire compressor rooms are pushing manufacturers to retrofit their existing assets with energy-optimised, smart air solutions.One of our key answers is the patented DEMAND=MATCH SYSTEM for fixed-speed compressors. Instead of running at constant output or needing an expensive VFD, this intelligent system smartly recirculates airflow inside the compressor so that delivery closely follows real-time plant demand. By keeping "demand matched to delivery", it cuts unnecessary load and unload cycles and pressure overshoot, delivering measurable impact of up to about 17 percent lower energy consumption in typical operating profiles while improving reliability and extending equipment life.Because DEMAND=MATCH is a capital-light add-on for compatible fixed-speed machines, it offers VFD-like savings without VFD-level complexity or cost. They can stabilise pressure, reduce specific energy consumption, and improve uptime on their installed base, accelerating the shift toward smarter, energy-optimised compressed air system.Since undetected air leaks can erode both energy efficiency and system lifespan, what's enabling greater adoption of automated leak detection tools among Indian SMEs?Undetected leaks can easily waste 20­30 percent of a plant's compressed air, forcing compressors to run longer, raising energy bills and shortening equipment life. For Indian SMEs working on thin margins, that combination of avoidable cost and reliability risk is a powerful trigger to adopt smarter, automated leak-detection tools.On the technology side, modern ultrasonic detectors, acoustic leak cameras and IoT flow and pressure sensors have become simpler and more affordable. They can `see' and log leaks even in noisy workshops, automatically map and quantify losses, and generate clear repair lists and reports without shutting the line down. Cloud dashboards and mobile apps mean a small maintenance team can monitor multiple lines and schedule repairs based on data rather than guesswork.Economically, this delivers quick payback. Fixing leaks cuts electricity consumption, frees up compressor capacity for future growth, and reduces unplanned stops caused by pressure drops. At the same time, growing focus on energy efficiency, ISO 50001-style energy management and government-backed efficiency programs is nudging SMEs to measure and reduce compressed-air waste. Taken together, smart tools, hard savings on power, and soft pressure from customers and regulators are all driving faster adoption of automated leak-detection solutions among Indian SMEs.
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